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Building a plexy case...

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  • Building a plexy case...

    I find it very hard to cut some decent looking rectangular holes at the back of my plexy case for the various I/Os (parallel/serial/usb ports, ps/2, etc...).
    I make some small holes with a drill for a start at the corners and then I use a Dremel tool with a cutting wheel to connect them, but I already destroyed 2 sheets of plexiglass.
    Could you suggest a better/proven technique?
    Also, any ideas on how to mount the PCI cards?

    Dimitris

  • #2
    I am about to make a Lexan case or Plexi glass case myself.
    I would think using a dremel with the correct wheel would be easy. Which cutting wheel are you using? I cut my metal case side with a fiber disc.
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    • #3
      Here is what I found works well.... Use a piece of sheet metal as a guide with a thin Dremel attachment such as the engraving tool. At high speeds the thin tool cuts through Plexi like butter because of the friction caused heat.
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      • #4
        Here ya go:
        http://www.dremel.com/productdisplay...1&Color=99CCFF
        Works like a dream! Used it on my harddrive mod. Even for large cuts where you can't use the arm, it's much easier to not have to hold the spinning, noisy dremel while making precise cuts. The dremel drill press looks cool, too. Haven't tried it, though.
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        • #5
          Do you have access to a saber saw? I cut all the holes for my player by drilling holes and then using a saber saw to square the cuts.

          -Jeff
          MPEGBOX - Plexiglass Computer
          www.mpegbox.com

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          • #6
            Get a laser pointer. Draw two dots where you want to cut between. Very quickly swing the pointer so the red dot goes back and forth between the two dots. This will make a very exact cut, but will take several Millinea
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            • #7
              Being that I don't own a dremel I used a soldering gun with a flat head attachment to cut through the plexi. It works like a knife through butter, if you can handle the fumes that is!

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              • #8
                you can always take it to a plastics company - they should cut all the holes out for you for about $50 and it will come out perfect

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                • #9
                  I took my plexi to a glass/plastic shop, and the guy just ran a glass cutter over the cutting line like 30 times, then folded along the crease to break apart the plexi.

                  It wouldn't work for small I/O slots though...that soldering attatchment sounds like a good idea, really smelly/messy though.

                  PS: I tried taking a spin saw to the plexi. Even though i was going EXTRA slow once that blade hit the plexiglass it broke off a huge chunk and sent it 40 feet into the air.
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                  • #10
                    Originally posted by SuperAJ:
                    <STRONG>PS: I tried taking a spin saw to the plexi. Even though i was going EXTRA slow once that blade hit the plexiglass it broke off a huge chunk and sent it 40 feet into the air. </STRONG>
                    Not that I've tried using a circular saw (or the like) to cut plexi, but I'd imagine you'd need a very fine-toothed blade. Something for masonry or finishing.
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                    • #11
                      I'll go buy a hot knife tip for my soldering gun and give it a try.
                      What about the PCI cards?
                      I am thinking of mounting (on the exterior side of the case-parallel to the motherboard) a metal sheet corner on top of the slots I'll cut on plexiglass for the PCI card's I/Os- then screw the cards on that with self tapping screws.
                      So each card will be supported by the actual PCI bus and a single screw... Do you think this will be strong enough for the car's environment.

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                      • #12
                        I used the general purpose spiral cutting bit, #561.
                        http://linear1.org/i/cutouts.jpg

                        Then I used miniature filesto get the edges smooth and corners square.

                        It's not shown in the pic, but I used fine snadpaper and Novus #2 polish to clean up those edges, and they have the *bling* now.

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                        • #13
                          I built my plexicase with nothing but a scoring knife, a soldering iron, and this alcohol like glue u can buy at a glass or plexiglass shop for glueing parts together.
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                          • #14
                            No offence Moahdib but your case is not exactly what I have in mind.
                            I don't want it to be glued together (by the way... this alcohol like glue is nothing but chloroform - used in anaesthesia back in the old days - try not to inhale it's fumes, it might cause renal/hepatic toxicity (=insufficiency!)),but bolted so that I can work in it and modify it easier and you didn't even made any holes on the plexy! You used that predrilled metal plate from a metal case.

                            [ 01-17-2002: Message edited by: Dimitris1976 ]

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                            • #15
                              flipping heck, its enough to make a person use metal
                              SensitivePsycho

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